Not Good!!!!!!

[WDaniels]

As I was pulling into the glass shop today, doing about 25 with the clutch in and I heard a real quick whiz sound and a small pop. So I says to myself "what the heck?" and shut off the truck. I see a little smoke come out of the grill and so I open the hood and what should I see?????? A hole in the top of my gear case cover about 3" long. I once again says to myself, "Self, I think my KDP has let loose!" I shut the hood and I look under the truck and there is the infamous, no good, low down rotten KDP laying on the ground! It looked like it didn't go through the gears but rolled along between the gear and case and when the clearance got to small, it broke the case. Not sure but hoping that is the case, anywise, here come the questions!

1. Has anyone done their own repairs on this? Should I take it to the cummins dealer, stealer ect? 2. Should I try to get the stealer or cummins to do this or help pay for this repair? 3. Where can I get a service manual. 4. When you do this do you remove the core support with the intercooler, air conditioner condenser, radiator or try to work with just the fan and shroud removed? The only one I have seen done, they took off everything in the front and also the Injection pump. They left nothing on the drivers side of the engine. 5. Can the gears be replaced without removing the components? 6. If it is this far apart, are there any bombs that might be easier to do if I have any money left. (I think this takes care of most if not all of my bombing moola!)7. Had a friend tell me that if the pin did just roll on the gears and if it took any chrome off the gears, replace the gears. Correct????? 8. The new case that came out on the 98. 5s and up with the tapered hole for the KDP, can I use that one on my 97?

These are just a few questions, I'm sure to have more, but any suggestions will be more than great appreciated!

Sorry this post is so long. But I'm not sure how to proceed properly.

Warren:{ :{

 

[Bigsaint]

Warren, sorry to hear. When time permits, empty your PM mailbox, couldn't reply to your ??? on the Frantz.



Scott W.

 

[Cummins Corvette]

Chris Strickland did the repair and took some pretty good pictures along the way. Here is a link to the info:



http://www.flex.net/~triplem/new/dowelpin.htm



That might be useful in determining if you want to tackle it.

 

[illflem]

Warren, Warren, Warren, tried to PM you that the jig was going back to Alaska last week, your box is full. Even left a note for you in one of your threads. Do understand your schedule. By all means use the new improved case. Cummins uses a special puller to remove the cam gear that eliminates taking the front end apart and removing the cam (most of the work), the repair would probably be cheaper from them. Joe G has posted a link to these instructions. Joe D doesn't recommend this method, I tend to follow his advice on anything concerning 12 valves. You can add a high performance cam from Piers while it's apart if you do the take it all apart method. If you do the work yourself you will need injection timing tools, you can then bump the timing up. If Cummins does the work they won't bump the timing. Choices, choices. Sorry to hear of your misfortune at least you might be able to use the pin over.

 

[ata]

Don`t know your mileage or month you bought it but a 1997 could still be in the 5 year 100000 mile engine warranty. Or it could be just out of it try the Stealer and see if they`ll work with you on it.

 

[sfelts]

Boy I am realy gitting woried about my ram not having a KDP jig now.

 

[Koa Man]

Don't wait for the jig. Just tab it. You can change the oil seal and check on the bolts under the cover using the tab method. It should take about 4 hours and the peace of mind is well worth it.

 

[WDaniels]

Hey all, my mail box is now empty. Only had about 20 messages. Didn't know that there was a limit on the PM box.



sfelts, DO YOUR KDP ASAP!!!!!!!!! My only saving grace was that I was coasting to a stop when it happened, maybe.



ata, have 137, and some change on the miles. I talked to the mechanic at the stealers a little while ago and he told me that D/C had dropped the KDP repair under warrentee from 18 hours to 6 hours for labor re-embursement. Sounds like D/C is trying to wiggle out of doing these thing all togeather.

 

[illflem]

The 18 hours to 6 hours reduction sounds about right if the dealers are now using Cummins' pull the cam gear method

 

[Deezul1]

A quick fix if the damage isnt toooo bad is to pull the cover and see if the gears are ok and if the case isnt totally trashed repair the hole with something like JB Weld. It only has to not leak. Someone here has done that with ok results as far as I have heard, cant remember who though.

Good Luck

John

 

[gitchesum]

I'm the one that did the JB Weld fix.

It still has a slight oil leak but it's not near as bad as it was when that little pin popped.



BUT, it if made a hole big enough for that pin to fall out, then I don't believe JB Weld is gonna help ya this time. Also, the KDP damage is usually right below the fan assembly where you can't see it. I'd be interested in seeing pictures of the damage if you can take some.

 

[WDaniels]

I will try to get some pictures if and when I can snag a digital camera and learn how to upload pictures to the net. Was looking at the top of the engine and behind the injector pump was the piece of timing gear cover laying back there. Am gonna try to get a 4mm borescope from work and see if I can find any more damage than just what is showing. So far the case only looks to be broke in just the top position. I'm gonna clean it off and inspect it better in a few minutes.

Just got back from the dealers and they said to come in monday morning and talk to the service manager, but that we could work something out. This was the owner of the dealership. So I figured if I could get them to cut their labor in half it would be worth my peace of mind. What do you guys think. Pay full price for the parts and 1/2 labor charges? I think that labor will be by far the biggest part of the bill. Boy do we pay the price for procrastination. The dealer has had 3 or for trucks in in the last 5 or 6 months for the kdp. So they are aware of it.

I looked at the pictures that a Chris Strickland posted and the job looks formatable for just one guy.

Will take pictures and keep ya all posted.



gitchesum,

did you install a new dowl pin? I thought that I read a post from someone here that said that the pin is just more than an alighnment pin. Something do do with timing? And that the pin had to be in the hole for the engine to run properly.

Warren

 

[gitchesum]

You do need to install a new pin. The dowel pin keeps the gear housing from moving out of place.

I was told that by several knowledgable people.

 

[Tardog]

WDaniels,



I've got that guilty feeling. Asking for your KDP jig kit. Sorry to hear the sh**ty news. Just reminds me of all the other CTD you see at stop lights, parking lots or driving. Talk about ticking time bombs. Hope the repair goes smooth and things get done right. Maybe now is the time for a few upgrades?. Although it is time someone stepped up to the plate and took responsibility for this design fault Cheers & good luck keep us posted on the repair.

 

[WDaniels]

Tardog,

DON'T feel guilty. Even if I had used the jig awhile back, I'm thinking that the pin was most of the way out even then. Of course, there wouldn't be the damage there is now but that's my fault not yours! Sometimes procrastination is the only thing I can find time for.

gitchesum was right about the damage, it is cracked behind the fan under the mount where the fan bolts to. Once I removed the fan bracket the crack was there. I'm at the point of taking off the timing gear cover so the wife went to town to get film so I can take a few pictures.

WD

 

[grtescpa]

Originally posted by WDaniels

As I was pulling into the glass shop today, doing about 25 with the clutch in and I heard a real quick whiz sound and a small pop. So I says to myself "what the heck?" and shut off the truck. I see a little smoke come out of the grill and so I open the hood and what should I see?????? A hole in the top of my gear case cover about 3" long. I once again says to myself, "Self, I think my KDP has let loose!" I shut the hood and I look under the truck and there is the infamous, no good, low down rotten KDP laying on the ground! It looked like it didn't go through the gears but rolled along between the gear and case and when the clearance got to small, it broke the case. Not sure but hoping that is the case, anywise, here come the questions!

1. Has anyone done their own repairs on this? Should I take it to the cummins dealer, stealer ect? 2. Should I try to get the stealer or cummins to do this or help pay for this repair? 3. Where can I get a service manual. 4. When you do this do you remove the core support with the intercooler, air conditioner condenser, radiator or try to work with just the fan and shroud removed? The only one I have seen done, they took off everything in the front and also the Injection pump. They left nothing on the drivers side of the engine. 5. Can the gears be replaced without removing the components? 6. If it is this far apart, are there any bombs that might be easier to do if I have any money left. (I think this takes care of most if not all of my bombing moola!)7. Had a friend tell me that if the pin did just roll on the gears and if it took any chrome off the gears, replace the gears. Correct????? 8. The new case that came out on the 98. 5s and up with the tapered hole for the KDP, can I use that one on my 97?

These are just a few questions, I'm sure to have more, but any suggestions will be more than great appreciated!

Sorry this post is so long. But I'm not sure how to proceed properly.

Warren:{ :{

What was your milege when it did your motor in?

 

[grtescpa]

Re: Re: Not Good!!!!!!

Originally posted by grtescpa



What was your milege when it did your motor in?

Never mind, my mistake, I just saw it was 137k.

 

[Cummins Corvette]

silver lining...

Maybe now would be a good time to throw in one of Piers's cams, eh?

 

[Swamp Donkey]

I was told the KDP jig was on it's way to me... ... Man I gotta get that done. Don't need to go through the hassle of fixing mine the hard way! I was told it was sent to me on tuesday or Wednesday so I am hoping for a monday arrival!



Then it is Alaska bound... ... ...

 

[danandamy]

Dang I guess I'm going to have to break down and do this. Time to do a search and find out the details



kdp on the edge dan